Interconnected deflectable panel and node and methods for producing same

ABSTRACT

Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes a panel interconnected with node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.

BACKGROUND 1. Field

The present disclosure relates generally to techniques for interconnecting a panel to a node, and more specifically to additively manufacturing techniques for printing a node with a tapered socket and interconnecting a panel by deforming the panel to conform to the shape of the tapered node.

2. Background

Additive Manufacturing (AM) processes involve the layer-by-layer buildup of one or more materials to make a 3-dimensional object. AM techniques are capable of fabricating complex components from a wide variety of materials. Typically, a freestanding object is fabricated from a computer aided design (CAD) model. Using the CAD model, the AM process can create a solid 3-dimensional object by using a laser beam to sinter or melt a powder material, which then bonds the powder particles together. In the AM process, different materials or combinations of material, such as, engineering plastics, thermoplastic elastomers, metals, and ceramics may be used to create a uniquely shaped 3-dimensional object.

Several different printing techniques exist. One such technique is called selective laser melting. Selective laser melting entails fusing (agglomerating) particles of a powder at a temperature below the melting point of the powder material. More specifically, a laser scans a powder bed and melts the powder together where structure is desired, and avoids scanning areas where the sliced data indicates that nothing is to be printed. This process may be repeated thousands of times until the desired structure is formed, after which the printed part is removed from a fabricator.

As AM processes continue to improve, more complex mechanical manufacturers are beginning to investigate the benefits of using additively manufactured parts in their designs. This is because, achieving efficient and effective manufacturing processes at low costs are perpetual goals of manufacturing sectors of many industries. For instance, the automotive industry, aircraft manufacturing, and other industries involved in the assembly of transport structures are constantly engaging in cost saving optimizations and looking for opportunities to improve manufacturing processes. Joining components with a multitude of shapes is one such area that has proven to be difficult to optimize. For instance, conventional manufacturing processes provide simple internal geometric shapes such as rectangles without additional features. These simple internal structures limit the configuration of components that may be interconnected. As a result, such manufacturing processes have a limited practical range, because they cannot be efficiently used to produce complex geometrical structures having the potential to provide new and different features and capabilities.

The recent advances in 3-dimensional printing or AM processes have presented new opportunities to build wide varieties and ranges of simple to very complex parts at relatively competitive costs. With AM, components with unique internal structures may be printed which may provide greater options when joining components. However, these unique shapes present a new unique set of challenges to joining components capable of deforming to fit the shape of more complex internal structures. For instance, a socket connection requires an internal fit that is not externally visible to a welder at a conventional manufacturing plant. Therefore, it can be difficult to join a socket component with a unique internal structure to a deformable component.

SUMMARY

Several aspects of techniques for joining an additively manufactured node to a component will be described more fully hereinafter with reference to 3-dimensional printing techniques.

One aspect of an apparatus includes an additively manufactured node having a socket. The apparatus includes a panel interconnected with the node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.

One aspect of a method includes printing a node having a socket by additive manufacturing. The method interconnects a panel with the node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The method engages the socket with an end portion of the panel. By the socket, the method shapes the surface layers on the end portion of the panel.

It will be understood that other aspects of co-printing interconnects with additively manufactured nodes will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only several embodiments by way of illustration. As will be realized by those skilled in the art, the co-printing of interconnects with additively manufactured nodes are capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of co-printing interconnects with additively manufactured nodes will now be presented in the detailed description by way of example, and not by way of limitation, in the accompanying drawings, wherein:

FIG. 1 illustrates an exemplary embodiment of an apparatus comprising a node and a panel interconnected with the node.

FIGS. 2A-2B illustrate an exemplary embodiment of an apparatus comprising a node and a panel engaged by narrowing a tapered socket.

FIGS. 3A-3C illustrate an exemplary embodiment of an apparatus comprising a node and a panel engaged by a widening tapered socket.

FIG. 4 illustrates an exemplary embodiment of an apparatus having a node with additively manufactured features designed to cause a panel to taper upon insertion into a node.

FIG. 5 conceptually illustrates a process 500 for utilizing co-printed internal features in joining a panel with a node.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appended drawings is intended to provide a description of various exemplary embodiments of additively manufacturing techniques for co-printing nodes and interconnects and is not intended to represent the only embodiments in which the invention may be practiced. The term “exemplary” used throughout this disclosure means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the invention to those skilled in the art. However, the invention may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form, or omitted entirely, in order to avoid obscuring the various concepts presented throughout this disclosure.

The use of additive manufacturing in the context of joining two or more parts provides significant flexibility and cost saving benefits that enable manufacturers of mechanical structures and mechanized assemblies to manufacture parts with complex geometries at a lower cost to the consumer. The joining techniques described in the foregoing relate to a process for joining additively manufactured parts and/or commercial of the shelf (COTS) components such as panels. Additively manufactured parts are 3-dimensionally printed by adding layer upon layer of a material based on a preprogramed design. The parts described in the foregoing may be parts used to assemble a motor vehicle such as an automobile. However, those skilled in the art will appreciate that the manufactured parts may be used to assemble other complex mechanical products such as vehicles, trucks, trains, motorcycles, boats, aircraft, and the like without departing from the scope of the invention.

One important issue that has been encountered in these industries is how to enable various disparate parts or structures to more efficiently interconnect. One such technique as disclosed herein involves the use of additive manufacturing. More specifically, by utilizing additive manufacturing techniques to print unique parts, it becomes simpler to join different parts and/or components in the manufacturing process. Such techniques can include deforming a portion of one part to conform to the internal shape of another. Additive manufacturing provides the ability to create complex internal shapes that were not previously possible using conventional manufacturing techniques. For example, a deformable panel having an end portion with a notch therebetween may be inserted into a node having a uniquely tapered shape. In the joining process, the end portion of the panel can deform into the internal shape of the node, which creates a stronger and simpler bond between the now interconnected components.

As will be discussed herein, a node is an example of an additively manufactured part. A node may be any 3-D printed part that includes a socket for accepting a component such as a panel. The node may have internal features configured to accept a particular type of component. Such features may be co-printed with the node. Alternatively or conjunctively, the node may be shaped to accept a particular type of component. For instance, the internal shape of a node may taper or expand to deform a deflectable panel according to the shape of the node's internal socket and then accept an adhesive to adhere the component to the node. However, as a person having ordinary skill in the art will appreciate, a node may be shaped to accept any type of component and utilize any internal design or shape and accept any variety of components without departing from the scope of the disclosure.

FIG. 1 illustrates an exemplary embodiment of an apparatus 100 comprising a node and a panel interconnected with the node. In some embodiments of the apparatus, the panel may comprise a deflectable panel. As shown, the apparatus 100 includes a node 105, a panel 110, and injection port 155, a socket 115, and a socket opening 190. The panel 110 includes surface layers 140, a core 145, and an end portion 150. The end portion 150 includes a filler material 125. The filler material may be a cross-linkable polymer such as an epoxy or a liquid adhesive. In some aspects of the apparatus, the end portion 150 may also include microballoons 120 in the filler material 125. In some aspects of the apparatus, the opposing surface layers 140 may be carbon fiber sheets. At least of a portion of the core 145 may be removed from between the surface layers 140. In some aspects of the apparatus, the end portion 150 may be without the core 145. Consequently, the filler material 125 may be injected into the available area near end portion 150 between the surface layers 140. The filler material 125 may be injected by way of the injection port 155. The microballoons 120 may be used to make the filler material 125 less dense without compromising structural integrity so that it may be compressed as shown in FIG. 1. For instance, microballoons may be incorporated into a material such as an epoxy to form a less dense slurry that can be deformed or compressed as necessary. However, a liquid adhesive, or any suitably curable and malleable substance may be used as the filler material 125 illustrated in FIG. 1.

The surface layers 140 may sandwich a core material 145 such as a honeycomb-like material or foam. The core 145 may remain between at least a portion of the surface layers 140, at least until the panel 110 is joined to the node 105. In order to join the node 105 and the panel 110, the end portion 150 of the surface layers 140 of the panel 110 may be compressed and deformed to fit into the socket 115 as it is being slid through the socket opening 190. As shown, the tapering within the socket 115 increases, or the socket narrows, as the distance from the socket opening 190 increases. The narrowing socket causes the panel 110 to compress. As a result, the end portion 125 of the panel 110 may be compressed against the node 105 so that it fits into the socket 115. In some aspects of the apparatus, a sealant and/or an adhesive may subsequently be injected into the socket 115 to fix the panel 110 to the node 105 in the deformed configuration. The notches along the socket 115 may provide a path for the sealant and/or adhesive, but are not necessary to effectively bond the panel 110 and the node 105.

FIG. 2A illustrates an exemplary embodiment of an apparatus 200 comprising a node 205 and a panel 210 engaged by a narrowing tapered socket. Similar to the panel 110 of FIG. 1, the panel 210 may be a deflectable panel capable of deforming by expansion or compression. As shown, the panel 210 includes a notch 215, surface layers 240, and a core 245. The node 205 includes a socket 295 with an adhesive layer 220 and a socket opening 290. FIG. 2B illustrates the apparatus 200 comprising the panel 210 interconnected with the node 205. In some aspects of the apparatus, the panel 210 may be inserted by way of the socket opening 290 into the socket 295 of the node 205. As shown, like in FIG. 1, the socket 295 comprises a tapered portion that narrows with increased distance from the socket opening 290. When the panel 210 is inserted, the notch 215 may compress by the tapered portion such that the end portion of the panel 210 surrounding the notch 215 conforms to the shape of the node 205. Moreover, as one skilled in the art will appreciate, the interface between the node and the panel may be similar to the socket 130 interface illustrated in FIG. 1 without departing from the scope of the disclosure.

The surface layers 240 may comprise a lightweight sturdy material, such as a composite material. Such composite materials may include carbon fiber. The composite material may have greater flexibility than the core material, which may be achieved by reducing the stiffness of the core 245. The flexibility of the surface panels 240 enables the end portion of the panel 210 that is inserted into the node 205 to become malleable and conform to the shape of the node socket 295 to form a secure bond. As will be discussed in the foregoing, a node may be configured to cause surface panels to conform to many different shapes and arrangements.

Additionally, the adhesive layer 220 may then surround the portion of the panel 210 that is enclosed within the node 205. In some aspects of the apparatus, the adhesive layer 220 is a film foam adhesive. In such aspects, film foam adhesives are harder than, cure faster than, and provide a stronger bond than liquid adhesives. The adhesive layer 220 may cure to fix the interconnected panel 210 with the node 205. An external heat source, such as an oven, may apply heat to the panel/node connection and cause the adhesive layer 220 to cure. As will be discussed below, the adhesive may be applied to the panel 210 prior to inserting the panel 210 into the node 205.

FIGS. 3A-3C illustrate an exemplary embodiment of an apparatus 300 comprising a node 305 and a panel 310 engaged by a widening tapered socket. FIG. 3A illustrates a node and interconnected panel prior to bonding, while FIGS. 3B and 3C illustrate the following steps of bonding the node and the panel. FIGS. 3A-3C include an apparatus 300. The apparatus 300 includes a node 305 and a panel 310. Similar to the panels 110 and 210, the panel 310 includes surface layers 340 and a core 345. The panel 310 also includes a deformable edge 335 and a notch 315. A portion of the core may be cut out to form the notch. Inside the notch is a pre-applied adhesive 325, that may foam and/or disperse when heated. The node 305 further includes a socket 330 and a socket opening 390.

As shown in FIG. 3A, the notch 315 may be created in the core 345. In some embodiments of the apparatus, at least a portion of the core 345 is removed. In some aspects of the apparatus, the adhesive 325 may be heated using an external source. When the temperature of the adhesive 325 reaches a particular point, the adhesive may begin to foam and expand into the socket 330. The adhesive 325 may be applied to the panel 310 prior to inserting the panel 310 into the node 305.

As shown in FIG. 3B, as the adhesive 325 begins to foam, it starts to fill the socket 330 of the node 305. As the adhesive 325 continues foaming, it may cause the panel 310 to expand, as shown in FIG. 3C. Thus, in contrast to the apparatus 200 of FIG. 2, the socket 330 may comprise a tapered portion that widens with distance from the socket opening 390. As a result, the deformable edges and the notch 335 may expand, causing the notch 315 to widen. In such aspects, the deformable edges 335 of the panel 310 may expand due to the action of the adhesive 325 to conform to the geometry of the socket 330 of the node 305. As discussed above, the surface layers 340 of the deformable ends 335 may have greater flexibility or compressibility than the core 345 because the stiffness of the core is reduced by the notch 315. Thus, the socket 330 expands the notch 315 according to the shape of the socket 330, in contrast to the panel that has the flexibility to fit the tapered socket in FIG. 2.

In the above example, the adhesive may be a film foam adhesive. However, in some aspects of the apparatus the adhesive 325 may be a liquid adhesive. The use of a liquid adhesive may require additional material and manufacturing time. For instance, when using a liquid adhesive, a liner may be applied between the notch 315 in the core 345 and the pre-applied adhesive 325. The liner is used to prevent the adhesive from migrating into the core 345. For instance, since the core 345 is typically made of a material with a honeycomb-like structure, a liquid adhesive could seep into the holes of the core's honeycomb structure in the absence of a liner.

Additionally a sealant may be necessary to seal the adhesive 325 to the node 305. Thus, when interconnecting the node 305 with the panel 310, a sealant may be pre-applied to at least one internal side of the node socket 330. Without the sealant, a proper seal between the socket 330 and the panel 310 may not be formed after the adhesive 325 cures.

Heat may then be applied to the apparatus, similar to the example above. As the temperature increases from the heat, the sealant may first begin to foam in order to form a seal around the edges of the socket 330. The adhesive 325 may subsequently foam, filling the cavity between the panel 310 and the sealant. In some aspects of the apparatus, the sealant may foam at a lower temperature than the adhesive 330. In such aspects, during the interconnecting process, heat may be applied to the node 305 and panel 310. As the temperature rises, the sealant would foam first. The heat may be applied such that the sealant has sufficient time to partially or fully cure before the temperature reaches the foaming point for the adhesive 325. After the adhesive 325 fills the cavity between the sealant within the socket 330 and the panel 310, the temperature may remain at a point that allows the adhesive 325 to cure and bond the node 305 and the panel 310 together, while also sealing the interface between the node 305 and the panel 310. The heat may be applied to the apparatus 300 from an external heat source.

Alternatively, when a film foam adhesive is used, as discussed above, applying sealant may be unnecessary for forming a seal between the node 305 and the adhesive 325 because the film foam adhesive is capable of forming the seal on its own. As a result, bonding time is reduced. Thus, when faster bonding times are needed, it may be important use a film foam adhesive in order to bypass the step of applying a sealant so that a faster bonding time can be achieved. Moreover, in some aspects of the apparatus, additively manufactured features may be printed in the node 305, where the node 305 acts as a tapering mechanism such that the panel 310 may deflect before the adhesive 325 flows through the node socket. The following figure illustrates a node with such printed features.

FIG. 4 illustrates an exemplary embodiment of an apparatus 400 having a node with additively manufactured features configured to cause a panel to taper upon insertion into a node. As shown, the apparatus 400 includes a node 405, a panel 410, and adhesive 425. The node 405 includes a tapering feature 455, socket 495, and socket opening 490. The panel 410 includes a core 445, and surface layers 440. As shown, a portion 415 of panel 410 surface layers 440 is without the core.

As discussed above, the tapering feature 455 expands with distance from socket opening 490. The tapering feature 455 is configured to cause the portion 415 of the surface layers 440 without the core 445 therebetween to deform, or taper, when the panel 410 is inserted into the node 405, and prior to the flow of the adhesive through the socket 495. As shown, the surface layers 440 may conform to the shape of the tapering feature 455. Unlike conventional manufacturing techniques, such as welding, additive manufacturing techniques enable the tapering features to be co-printed inside of the node. It is often difficult to add such features internal to a structure with conventional manufacturing techniques. Moreover, the tapering features 455 illustrated in FIG. 4 are merely exemplary illustration of a feature that may be co-printed with a node to shape a panel or other component according to the geometry of the tapering feature. In fact, any co-printed feature that is configured to accept a component, or portion of a component (e.g., surface layer of a panel) may be utilized in order to increase customizability without departing from the scope of the disclosure.

Thus, additive manufacturing techniques allow for deforming or deflecting a component such as a panel prior with co-printed features prior to affixing the panel to a node. The deflections allow for a more stronger and more customizable interconnection that was not previously achievable. Stronger interconnections are beneficial to highly complex manufactured structures that may be under a lot of stress such as land, sea, and air vehicles. However, one having ordinary skill in the art will appreciate that the above techniques are applicable to any structure or manufacturing process requiring strong adhesion and/or faster bonding times.

FIG. 5 conceptually illustrates a process 500 for utilizing co-printed internal features in joining a panel with a node. The panel may be a deflectable panel configured to have greater flexibility by reducing the stiffness of a core material between surface layers of the panel. The process 500 may be performed by a mechanical device. The process 500 begins when instructions to additively manufacture a part are provided. The process 500 may be performed in connection with the apparatuses 100, 200, 300, and 400 discussed above with respect to FIGS. 1-4.

At 505, the process 500 prints a node having a socket by additive manufacturing. The process 500 interconnects (at 510) a panel with the node. The panel may include opposing surfaces layers and a core between at least a portion of the surface layers. As discussed above, at least a portion of this core may be removed during the joining process. The process 500 engages (at 515) the socket with an end portion of the panel. After engaging the socket with the end portion, the process 500 shapes (at 520) the surface layers on the end portion of the panel based on the shape of the socket. For instance, as shown in FIGS. 1 and 2, the deflectable end portions of the panel may have sufficient flexibility to compress and fit into a tapered node socket. This may be achieved by reducing the stiffness of the core. Conversely, as shown in FIGS. 3 and 4, for example, the deflectable ends may have the flexibility to expand and fit into a wider socket. Similarly, this may be achieved by removing at least a portion of the core from the expanded ends, which reduces the stiffness of the core.

The ability to additively manufacture nodes creates the opportunity to shape components such as panels to provide stronger interconnections. By tapering or expanding the ends of the panels, simpler and more cost efficient approaches for joining a node and a panel can be achieved. Additive manufacturing provides the ability to generate parts with geometric features that are not otherwise possible using conventional manufacturing techniques.

The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to other techniques for printing nodes and interconnects. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout the disclosure, but are to be accorded the full scope consistent with the language claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. § 112(f), or analogous law in applicable jurisdictions, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.” 

What is claimed is:
 1. An apparatus, comprising: an additively manufactured node having a socket; and a panel interconnected with the node, the panel comprising opposing surface layers and a core between at least a portion of the surface layers, wherein the socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.
 2. The apparatus of claim 1, wherein the surface layers on the end portion of the panel are without at least a portion of the core between them.
 3. The apparatus of claim 2, wherein the panel further comprises a material between the surface layers on the end portion of the panel, wherein when the stiffness of the core is reduced, the material has greater flexibility than the core.
 4. The apparatus of claim 2, wherein the panel further comprises adhesive filler material comprising a plurality of microballoons between the surface layers on the end portion of the panel.
 5. The apparatus of claim 1, wherein a section of the core extends between the surface layers of the end portion of the panel, and wherein the section of the core comprises a notch.
 6. The apparatus of claim 5, wherein the adhesive extends from the notch into the socket.
 7. The apparatus of claim 6, further comprising a sealant between the panel and the socket to seal the adhesive in the socket.
 8. The apparatus of claim 5, wherein the socket comprises a tapered portion that narrows with distance from the socket opening, and wherein the notch is compressed by the tapered portion.
 9. The apparatus of claim 5, wherein the socket comprises a tapered portion that widens with distance from the socket opening, and wherein the notch is expanded with the tapered portion.
 10. A method comprising: printing a node having a socket by additive manufacturing; interconnecting a panel with the node, the panel comprising opposing surface layers and a core between at least a portion of the surface layers; engaging the socket with an end portion of the panel; and by the socket, shaping the surface layers on the end portion of the panel.
 11. The method of claim 10, further comprising removing the core between at least a portion of the surface layers on the end portion of the panel.
 12. The method of claim 11, further comprising injecting a material between the surface layers on the end portion of the panel, wherein the material has greater compressibility than the core.
 13. The method of claim 11, further comprising injecting a plurality of microballoons between the surface layers on the end portion of the panel.
 14. The method of claim 10, wherein a section of the core extends between the surface layers on the end portion of the panel, and the method further comprising cutting a notch in the section of the core.
 15. The method of claim 14, further comprising pre-injecting an adhesive that extends from the notch into the socket.
 16. The method of claim 15, further comprising: applying heat to the sealant; and causing the sealant to expand around the panel and the socket to seal the adhesive in the socket.
 17. The method of claim 14, wherein the socket comprises a tapered portion that narrows with distance from the socket opening, the method further comprising compressing the notch by the tapered portion.
 18. The method of claim 14, wherein the socket comprises a tapered portion that widens with distance from the socket opening, the method further comprising expanding the notch with the tapered portion.
 19. The method of claim 18, wherein the shaping the surface layers on the end portion of the panel further comprises using a foaming adhesive in the socket. 